I normally don't get involved---but, just this once:
Board re-design is your best bet, unless they're in house---your only option
is an "adapter" ( a connector contact from a terminal junction
family---male, one end; approx .014 less than board hole dia. and the wire
receptacle end large enough for the component lead )---use two different
solders (if the contacts are Au plated, and they are---double dip )---now,
the hard part---update the dwg./parts list with the new solder and contact
and any supporting compound that is not already in your documentation.
Sorry this is taking so long---I had to take time out to bathe my dog, after
he was sprayed by a skunk.
-----Original Message-----
From: Stephen R. Gregory <[log in to unmask]>
To: [log in to unmask] <[log in to unmask]>
Date: Monday, August 24, 1998 6:55 PM
Subject: [TN] Assy: How can a square peg fit in a round hole?
>Hi ya'll!
>
>I'm pretty sure that one or two of you "ol' crusty" types (I mean that in a
>GOOD way), have run across this problem I have a time or two. I have this
>board I'm building in a quasi "prototype/pre-production" run that has a PTH
>rectifier diode installed vertically...some of you have may have guessed
what
>my problem is already from my subject, the hole's too small.
>Lead diameter is right around .050" +/- a mil or two, guess what the hole
size
>is? .050", +/- a mil or two...that's just peachy ain't it? It goes two
times
>per board, and we gotta' build a hundred of these, maybe two hundred.
>
>So tell me, what have all you "old salts" done to make a square peg to fit
in
>a round hole? I've had some REALLY GOOD suggestions from some "experts"
here,
>one was to get a dremel and drill the hole out (sounds good to
me!...snicker),
>another was to get a can of "Freeze-it" and spray the diode leads with it,
>then hurry up and stuff it in the hole before it warms up and
expands...that
>sounded pretty keen too, except it's hard to hold the diodes when you're
>wearing mittens to keep from getting your digits frostbitten.
>
>So I told my "helpers" that I really appreciated their suggestions, but
that I
>would like to give the technet a chance to offer some guidance to me, and
that
>no-way were the suggestions from the TechNet going to be as good as theirs,
>but I wanted to see what popped up...and I would come to them if I needed
>anymore "help"...in other words, don't call me, I'll call you.
>
>I'm sure glad this is email, it would be kinda' hard to carry on this
>conversation with my tongue in my cheek like this...
>
>So, what's the verdict? Am I hosed? I looked around on the NET trying to
find
>the same spec'd diode with smaller lead diameters, but no joy. The only two
>companies I found were Motorola and General Instruments, and they both
listed
>the same thing that I have now.
>
>Is there any trick that any of you have done to make something like this
work?
>I'm afraid if I don't figure something out, I'll be in mittens spraying
diodes
>with freeze-it on the production floor...ya' gotta save me!
>
>-Steve "soon to be numb-fingers" Gregory-
>
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